Plate Crown Control Using Learned Roll Wear Correction
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Solution Overview
Problem
Current plate crown control devices face challenges in achieving accurate setting values for work roll bending and curve roll shift due to limitations in predicting roll wear and thermal expansion, leading to errors in plate crown measurement and flatness issues, especially in steel rolling where high temperatures and varying alloy components complicate the behavior of rolls.
Innovation Solution
A plate crown control device that uses a processor and memory to calculate and correct setting values for bending forces and shift positions based on real-time measurements from plate crown and flatness meters, incorporating learning algorithms to adjust for roll wear and thermal expansion, thereby improving prediction accuracy and reducing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If correction of model error is performed by equally dividing deviation between crown actual value and prediction value to mechanical plate crown prediction values of stands, then learning can be performed, but flatness on delivery side of stands deteriorates and bending forces and shift positions reach mechanical and operational limit values
Solution Approach 1:
The patent applies local quality by differentiating the correction approach for different stands. Instead of equally dividing correction across all stands, the system calculates individual correction amounts for each stand based on their specific mechanical plate crown prediction values and operational characteristics. This allows optimal correction distribution that maintains flatness while achieving accurate plate crown control.
Solution Approach 2:
The patent changes parameters by introducing correction amounts that are calculated based on the difference between crown actual value and prediction value, distributed proportionally to mechanical plate crown prediction values of each stand. This parameter-based correction approach adjusts bending forces and shift positions dynamically to avoid reaching mechanical limits while maintaining control accuracy.
2Measurement precision
If correction amounts are calculated based on difference between crown actual value and prediction value and distributed according to mechanical plate crown prediction values of stands, then setting accuracy is improved, but device complexity increases
Solution Approach 1:
The patent implements feedback by continuously measuring the actual plate crown value, comparing it with the prediction value, and using the difference (deviation) to calculate correction amounts. This feedback loop is integrated into the setting calculation process, allowing the system to automatically adjust bending forces and shift positions based on real-time measurement data, improving accuracy without requiring complex external intervention.
Solution Approach 2:
The system performs self-service by automatically calculating and applying correction amounts to the setting values for each stand. The correction calculation is integrated into the existing control system, where the plate crown control device autonomously adjusts bending forces and shift positions based on measured deviations, eliminating the need for manual intervention or complex external correction mechanisms.
3Manufacturing precision
If dynamic feedback control is applied using plate crown meter and flatness meter, then high-quality material production is achieved, but control cannot be applied to most distal end portion of material
Solution Approach 1:
The patent applies preliminary action by performing setting calculation correction before the rolling process for each material. The system calculates appropriate bending forces and shift positions for all stands based on predicted plate crown values and measured deviations from previous materials. This pre-calculated setting information is then applied to ensure accurate plate crown control from the beginning of the rolling process, including for the distal end portion that cannot be controlled by dynamic feedback during rolling.
Data Source
AI summary
A plate crown control device controls tandem rolling equipment based on delivery-side plate crown setting calculation values of stands calculated by setting calculation, mechanical plate crown setting calculation values of the stands, and setting values of bending forces and shift positions of the stands. A processor calculates first learning current values based on differences between mechanical plate crown observation values and mechanical plate crown actual calculation values. The processor prorates first learning values with first learning current values and smoothing gains and updates the first learning values. The processor calculates, in the setting calculation for the next and subsequent materials, setting values of bending forces and shift positions of the stands using mechanical plate crown setting calculation values after correction obtained by adding the first learning values to the mechanical plate crown setting calculation values.